Development and Testing of an Innovative Multi-Layer Plate Deployment (MLPD) Mechanism for Compact Aerospace Applications

Maximizing internal volume efficiency is a critical design consideration in compact aerospace applications, where available space is limited and every cubic centimeter must serve a function. Systems such as high-powered model rockets, CubeSats, and small-scale reentry vehicles require miniaturized, multifunctional components that minimize structural cutouts and preserve internal payload volume. One such component that plays a vital role in flight control and recovery operations for sounding rockets is the airbrake. Airbrakes are aerodynamic control surfaces used to increase drag and decelerate a vehicle during flight, commonly employed in aerospace systems for altitude and velocity control. Their effectiveness in modulating ascent profiles makes them critical components in rocket recovery and precision landing systems. Traditional airbrake designs can often be categorized into sliding and hinged-plate (umbrella) airbrakes as shown in Fig 1. Sliding airbrakes function by extending a plate laterally from the rocket body to create additional drag; however, they suffer from limited deployment area due to constraints on maximum size by the rocket body tube, leading to reduced braking effectiveness. Hinged airbrakes, on the other hand, rotate outward from the rocket body, providing a larger deployed surface area and improved drag generation. Despite this advantage, hinged designs require a greater portion of the rocket’s outer structure to be cut away to accommodate the full range of fin motion, introducing challenges to the structural integrity of the airframe. Additionally, hinged mechanisms are mechanically more complex and susceptible to aerodynamic loading issues at high speeds. Both designs face trade- offs between achievable braking force, structural robustness, and mechanical reliability, limiting their performance under demanding flight conditions. To address these challenges, a novel Multi-Layer Plate Deployment (MLPD) airbrake system has been developed. This design incorporates a sandwich-like structure, allowing multiple plates to be stacked within a compact volume and sequentially deployed using variable motion controlled by a single actuator shaft. The MLPD airbrake increases the effective braking surface area without requiring large cutouts in the rocket body, preserving structural integrity. By solving the area limitations of sliding airbrakes and minimizing the time required for deployment, the MLPD system enhances flight reliability and improves aerodynamic braking performance for precision altitude control.